1. Process Mechanisms of Single Screw Extrusion Dr Xueqin (Amy) Liu Research Assistant Intelligent System & Control School of Electronics, Electrical Engineering & Computer Science

2. Xueqin Liu Mechanisms of Single Screw Extrusion June 1, 2011 Slide 2 Presentation Outline Standard set-up of SSE Process mechanisms Pressure development Inferential Viscosity Laboratory SSE

3. Xueqin Liu Mechanisms of Single Screw Extrusion June 1, 2011 Slide 3 Standard Set-up of Single Screw Extruder

4. Xueqin Liu Mechanisms of Single Screw Extrusion June 1, 2011 Slide 4 Process Analysis Identification/selection of manipulated variables, disturbance variables, and controlled variables is required for the proper design of control systems. partially reproduced from Iqbal, 2010

5. Xueqin Liu Mechanisms of Single Screw Extrusion June 1, 2011 Slide 5 Process Mechanisms Clamp-ring Adapter Reproduced from Tadmor and Klein, 1970

6. Xueqin Liu Mechanisms of Single Screw Extrusion June 1, 2011 Slide 6 Melting Mechanism Adapter

7. Xueqin Liu Mechanisms of Single Screw Extrusion June 1, 2011 Slide 7 Pressure Development

8. Xueqin Liu Mechanisms of Single Screw Extrusion June 1, 2011 Slide 8 Pressure Drop Through the Die

9. Xueqin Liu Mechanisms of Single Screw Extrusion June 1, 2011 Slide 9 Inferential Viscosity In-line rheometer Viscosity calculated from pressure drop and throughput rate (here linear with speed) –

10. Xueqin Liu Mechanisms of Single Screw Extrusion June 1, 2011 Slide 10 Inferential Viscosity Can be achieved using suitable rheological model and appropriate rheological parameters Provides initial estimate of material viscosity –

11. Xueqin Liu Mechanisms of Single Screw Extrusion June 1, 2011 Slide 11 Laboratory Single Screw Extruder Killion KTS-100, 25mm SSE (1995) with in-line rheometer

12. Xueqin Liu Mechanisms of Single Screw Extrusion June 1, 2011 Slide 12 References 1.Cogswell, F. N., Polymer melt rheology: A guide for industrial practice. Abington: Woodhead Publishing Ltd, 1981. 2.Han, C. D., What is the role of "pressure" in the use of capillary and slit flows to determine the shear-rate dependent viscosity of a viscoelastic fluid. Polymer engineering and science, 2008, 48(6): 1126 - 1140. 3.Liang, J.. Estimation of entry pressure drop during conical die flow of carbon black-filled rubber compound. Journal of Reinforced Plastics and Composites, 2004, 23(3): 1355-1363. 4.Cogswell, F. N., Measuring the extensional rheology of polymer melts. Transactions of the Society of Rheology, 1972, 16(3): 383 - 403. 5. C. Rauwendaal, Polymer Extrusion (4th edition). Carl Hanser Verlag, Munich, 2001.

13. Xueqin Liu Mechanisms of Single Screw Extrusion June 1, 2011 Slide 13 References 6.Cogswell, F. N., et al., Converging Flow of Polymer Melts in Extrusion Dies. Polymer Engineering and Science, 1972,12: 64 - 73. 7. McAfee, M. (2005). A soft sensor for viscosity control of polymer extrusion. Phd thesis, Queen’s University Belfast. 8.M. H. Iqbal, U. Sundararaj, and S. L. Shah, “New approach to develop dynamic gray box model for a plasticating twin-screw extruder,” Industrial & Engineering Chemistry Research, vol. 49, no. 2, pp. 648– 657,2010. 9.X. Liu, K. Li, M. McAfee, and J. Deng, “‘soft-sensor’ for real-time monitoring of melt viscosity in polymer extrusion process,” in Decision and Control (CDC), 2010 49th IEEE Conference on, 2010, pp. 3469 – 3474. 10.B. H. Maddock, “Measurement and analysis of extruder stability,” SPE Journal, vol. 20, pp. 1277–1283, 1964.

14. Xueqin Liu Mechanisms of Single Screw Extrusion June 1, 2011 Slide 14 Thank you for your attention